Rigid Urethane Self-Skinning Foam Top Frame, Pallet Support Board, and Pallet

ABSTRACT

The present invention provides a top frame made from a thermoset foam material. The top frame includes a pair of substantially parallel sides and a pair of substantially parallel ends connected to the sides to form a generally rectangular frame structure. The frame structure has an inner layer and outer surface defining a thickness. The thermoset foam material varies in density along the frame structure thickness such that the density of the thermoset foam material is greatest near the frame structure outer surface to form a hard outer shell.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present Application claims the benefit of U.S. ProvisionalApplication No. 61/411,501, filed Nov. 9, 2010, the contents of whichare incorporated herein by reference.

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

FIELD OF THE INVENTION

The present invention generally relates to an improved top frame, palletsupport board, pallet, dolly, insulated tote, and other related items,and a material and process for making the same.

BACKGROUND OF THE INVENTION

Plastic pallets have long been used to transport and store goods andother materials. Plastic top frames have been used with the plasticpallets to secure a load of goods or materials to the pallet. The framesallow for placement of bands or straps around the pallet and goods toprevent the load from slipping on or falling off the pallet.

The load is placed on the pallet, and the top frame is placed on top ofthe load. The load is then secured to the pallet by wrapping straps orbanding around the pallet, the load, and the top frame. The banding canbe plastic, metal or other suitable material. The top frame can alsofacilitate stacking of pallets during transport or storage.

Additionally, plastic pallet support boards have been used to allowpallets of different sizes to be more easily handled. For example, awarehousing operation may employ different sized pallets to move orstore goods or materials. The different sized pallets are placed onpallet support boards to facilitate handling in a more standardizedmanner. Some users place goods or materials directly on the palletsupport boards. Known plastic pallets can be heavy. Known plasticpallets, pallet support boards, and top frames are also more expensivethan their wooden counterparts.

Plastic dollies are used to move materials from one place to another.Plastic dollies have casters to allow loads to be placed upon the dollyand more easily move the load from place to place. Known dollies aremade from a thermoplastic material, and are rotomolded, making themhollow. Dollies made this way are subject to breakage due to use andabuse. These dollies are also heavy and expensive to manufacture.

Totes are currently sometimes used to carry materials requiringtemperature control. This requires the materials to be placed ininsulated bags, and the bags placed inside the totes. Also, styrofoamcontainers are sometimes used. Items are placed in the styrofoamcontainers, which are then placed inside the totes. Styrofoam containersdo not stand up to repeated use.

Many of the prior transportation and storage components used in theindustry have one or more problems. Some are formed with expensiveand/or heavy materials, such as thermoplastic. Others are formed fromwood or fiberboard, which can crack or rot. Some use multiple extrudedpieces which require additional assembly and risk becoming loose (e.g.,a top frame formed from extruded top frame arms connected by cornerpieces). Others have hollow portions that can become contaminated ifcracked. The present invention is an improvement on all of these.

SUMMARY OF THE INVENTION

The present invention relates to an improved pallet, top frame, palletsupport board, dolly, insulated tote, and other similar items formedfrom a thermoset foam material. The thermoset foam material providessufficient strength characteristics while being lightweight and easy tohandle.

In one embodiment, a top frame made from a thermoset foam material isprovided. The top frame includes a pair of substantially parallel sidesand a pair of substantially parallel ends connected to the sides to forma generally rectangular frame structure. The frame structure has aninner layer and an outer surface. The frame structure also has athickness. The top frame is made from a thermoset foam material. Thethermoset foam material varies in density along the frame structurethickness such that the density of the thermoset foam material isgreatest nearest the outer surface to form a hard outer shell.

In another embodiment, the top frame for use in combination with atransport item, such as a pallet, carrying goods is provided. The topframe includes a unitary frame formed from a thermoplastic foam havingan interior foam portion and an exterior surface foam portion. Theinterior foam portion has a first foam density. The exterior surfacefoam portion has a second foam density greater than the first foamdensity. The exterior foam portion forms a hard skin surrounding theinterior foam portion.

In another embodiment, a pallet support board made from a thermoset foammaterial is provided. The pallet support board includes a generallyrectangular deck having an inner layer and an outer surface defining athickness. Again, the thermoset foam material varies in density alongthe pallet support board thickness such that the density of thethermoset foam material is greatest near the pallet support board outersurface to form a hard outer shell.

In a further embodiment, a pallet made from a thermoset foam material isprovided. The pallet includes a deck having an inner layer and an outersurface defining a thickness. Similar to the top frame and palletsupport board, the thermoset foam material varies in density along thepallet thickness such that the density of the thermoset foam material isgreatest near the pallet outer surface to form a hard outer shell. Inother embodiments, the top frame, pallet support board, and palletinclude a substrate coated with a polyurea material.

In another embodiment a tote made from a thermoset foam material isprovided. The tote includes a pair of opposing side walls and a pair ofopposing end walls. It also includes a lid having a first side and asecond side. The tote includes a liner. The liner is sized and shaped tobe inserted into the tote. The tote also includes a cover to be placedon top of the liner, and still allow the lid to completely close.

In a further embodiment a dolly made from a thermoset foam material isprovided. The dolly has includes a body. The body includes a caster ateach corner. The body includes an elevated edge and an opening in itscenter.

The pallet support board, top frame, pallet, tote, and dolly can be madeof a “self-skinning” foam. Alternatively, they may also have a generallyuniform density throughout their thickness.

Thermoset foam is lighter and less expensive than its plasticcounterparts in the manufacture of pallets, top frames, or palletsupport boards and other related components. Moreover, thermosetmaterials do not have the memory or “creep” inherent in thermoplastics,rather the material keeps its shape when heated and over extended use.Additionally, such items made according to the present invention aremade of a single piece.

Other features and advantages of the invention will be apparent from thefollowing specification taken in conjunction with the following Figures.

BRIEF DESCRIPTION OF THE FIGURES

To understand the present invention, it will now be described by way ofexample, with reference to the accompanying Figures in which:

FIG. 1 is a top perspective view of a pallet support board in accordwith an embodiment of the present invention.

FIG. 2 is a side plan view of a pallet support board in accord with anembodiment of the present invention.

FIG. 3 is an end plan view of a pallet support board in accord with anembodiment of the present invention.

FIG. 4 is a top plan view of a pallet support board in accord with anembodiment of the present invention.

FIG. 4A is a top perspective view of a pallet support board in accordwith an embodiment of the present invention.

FIG. 5 is a top perspective view of a top frame in accord with anembodiment of the present invention.

FIG. 6 is a side plan view of a top frame in accord with an embodimentof the present invention.

FIG. 7 is an end plan view of a top frame in accord with an embodimentof the present invention.

FIG. 8 is a top plan view of a top frame in accord with an embodiment ofthe present invention.

FIG. 8A is a top perspective view of a top frame in accord with anembodiment of the present invention.

FIG. 9 is a top perspective view of a pallet in accord with anembodiment of the present invention.

FIG. 10 is a cross-sectional view of a reinforcement in accord with anembodiment of the present invention.

FIG. 11 is a cross-sectional view of a reinforcement in accord with anembodiment of the present invention

FIG. 12 is a cross-sectional view of a reinforcement in accord with anembodiment of the present invention.

FIG. 13 is a cross-sectional view of a reinforcement in accord with anembodiment of the present invention.

FIG. 14 is a perspective cross-sectional view of a top frame in accordwith an embodiment of the present invention.

FIG. 15 is a schematic view showing the process for making self-skinningfoam in accord with an embodiment of the present invention.

FIG. 16 is a plan view of a dolly in accord with an embodiment of thepresent invention.

FIG. 17 is a side view of a dolly in accord with an embodiment of thepresent invention.

FIG. 18 is a perspective view of an insulated tote in accord with anembodiment of the present invention.

FIG. 19 is a perspective view of an insulated tote in accord with anembodiment of the present invention.

FIG. 20 is a cross-sectional perspective view of an insulated tote inaccord with an embodiment of the present invention.

FIG. 21 is a perspective view of a dolly in accord with an embodiment ofthe present invention.

FIG. 22 is a perspective view of an insulated tote in accord with anembodiment of the present invention.

FIG. 23 is a perspective view of an insulated tote in accord with anembodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

While this invention is susceptible of embodiments in many differentforms, there is shown in the Figures, and will herein be described indetail, preferred embodiments of the invention with the understandingthat the present disclosure is to be considered as an exemplification ofthe principles of the invention, and is not intended to limit the broadaspect of the invention to the embodiments illustrated.

FIGS. 1 through 4A show a pallet support board 10 made in accord with anembodiment of the present invention. The pallet support board 10 is madefrom a thermoset foam material. Suitable thermoset foam materials caninclude polyurethane foam, urethane foam, epoxy foam, phenolic foam,syntactic foam, polyaspartic foam, and hybrids of these foams. In apreferred embodiment, polyurethane foam is used. The pallet supportboard 10 includes a generally rectangular deck 12 having an inner layer13 and an outer surface 15. The inner layer 13 and outer surface 15define a thickness 18. A typical thickness 18 is on the order of ¼ to 1½inches, however, the deck 12 can be of any suitable thickness for itsintended application. The deck 12 also includes a pair of opposing ends20, and a pair of opposing sides 22. The pallet support board 10 can bemade in any size suitable for its application.

In an embodiment, both of the opposing ends 20 and opposing sides 22include tapered sections 24 along an outer edge 25. It will beunderstood that the tapered sections 24 need not be on both the opposingends 20 and opposing sides 22. Furthermore, as shown in FIG. 4A, thetapered sections 24 may extend substantially along the entire length ofone or both of the opposing ends 20 and/or opposing sides 22.

In one embodiment, the tapered sections 24 are tapered across thethickness 18 from an upper surface 14 and lower surface 16. The taperedsections 24 are sized and located to accept forklift tines duringhandling and transport. The deck 12 also includes on at least one of theupper surface 14 or lower surface 16 banding slots 28 to accommodatebands used to secure the pallet support board 10 to an associated loadedpallet or other item placed on the board. In one embodiment, at leastportions of the upper surface 14 and/or lower surface 16 of the palletsupport board 10 have an exterior skin that is rubberized or texturizedto help prevent slippage between the pallet support board 10 and theload with which it is used. The pallet support board 10 may include handholds 26 which extend through at least part of the thickness 18.

In an embodiment of the pallet support board 10, the foam varies indensity along the thickness 18 of the deck 12 such that the density isgreater nearest the outer surface 15, including upper and lower surfaces14 and 16, than in the center of the thickness 18. The density can varycontinuously across the thickness 18, or there can be two or morediscrete layers of similar density, e.g., an inner density and an outer(i.e., skin) density. The density of the foam material near the outersurface 15 such that the foam creates a hard outer shell. Such materialmay include a “self-skinning” foam further described below. The higherdensity foam at the outer surfaces provides impact resistance anddeflection strength as well as a hard surface and a stiff structure. Inother embodiments, the pallet support board 10 is a generally uniformdensity throughout the thickness 18.

In a preferred polyurethane foam embodiment, the foam is created frommixing two components: isocyanate and polyol. The formulation of thecomponents is determined by the desired characteristics of the finishedfoam. In a preferred embodiment, the foam has a density in the range of6 to 27 pounds per cubic foot, and more preferably in a range between 8and 18 pounds per cubic foot, with higher densities at the outer surface15, including upper and lower surfaces 14 and 16.

To make a polyurethane foam pallet support board 10, the isocyanate andpolyol are mixed either mechanically or manually. The polyol isavailable from Burtin Polymer Laboratories of Cartersville, Ga. In anembodiment of the invention, fire retardant materials may be added intothe foam mixture to enhance resistance to fire. Coloring agents can alsobe added to the foam mixture for any desired color. The mixture isinjected or poured into a tool cavity, where it will remain until cured.The foam is preferably molded using either reactive injection molding(RIM) or resin transfer molding (RTM) processes, although any suitablemolding process may be used, including manually mixing and pouring themixture into a mold cavity. After the mixture is poured into the mold,it must cure for a specified time depending on the formulation of thecomponents. After curing, the foam pallet support board is ejected fromthe tool cavity either mechanically or manually.

One embodiment of the process 600 by which the self-skinning urethanefoam is made is shown in FIG. 15. The process 600 includes a first tank602 containing isocyanate. A second tank 604 contains polyol. Thematerials from tanks 602 and 604 are directed to a meter 606. The meter606 measures the desired amounts of isocyanate and polyol and their flowrates. The polyol is preferably heated at the meter 606 by a heater 608to a temperature of approximately 125 degrees Fahrenheit. Thermallyactivated foam is preferable to chemically activated foam. Aftermetering, the polyol and isocyanate are combined and inserted into analuminum mold 610.

It has been found that eight pound per cubic foot density foam,constrained by the mold 610 creates the desired density and strength ofmaterial and the self-skinning feature of the foam. This desired densityof the molded foam is between ten and nineteen pounds per cubic feet.Additionally, it has been found that maintaining the temperature of themold 610 to between 80 and 100 degrees Fahrenheit results in the skinforming with the desired results. The closer to 80 degrees, the thickerthe outer skin. It is believed that these temperatures result in theurethane in the foam solidifying where the foam meets the mold 610. Ithas also been found that keeping the temperature of the materials warmerthan the mold 610 before the material is inserted into the mold 610could be important to proper skin formation. The self-skinning can alsobe accomplished using a foam formulation that would provide suchskinning.

The mold 610 interior surfaces may be textured using known means such assandblasting or acid etching. This creates a corresponding texture 612(see FIG. 14) in the exterior surface of the outer skin of a productformed in the mold.

In addition, the mixture of polyol and isocyanate can have one or morefillers added to reduce the cost of manufacture. Suitable fillersinclude ceramic microballoons, recycled glass, calcium carbonate andwollastonite. Ceramic microballoons provide an additional advantage inthat they are 20% lighter than the foam, and add strength to the foam.Additionally, differing formulations for the polyol and isocyanateformulations can provide differing outer skin thickness.

In operation, the process includes the steps of providing a desiredformulation of iscoyanate and polyol. At least one of the isocyanate andpolyol are heated to a temperature of between 80 and 125 degreesFahrenheit. The iscoyanate and polyol are combined to form a foamsolution. The foam solution is injected into the mold 610.Alternatively, the isocyanate and polyol are injected separately andmixed within the mold 610. The mold 610 is heated to a temperature ofbetween eighty and one hundred degrees Fahrenheit, preferably nearereighty degrees. After injection, the foam mixture expands to fill themold 610. The mixture is left to cure within the mold 610. The mold 610constricts the expansion of the foam mixture to increase its density tothe desired density. After curing, the finished product is removed fromthe mold.

In another embodiment, the finished foam pallet support board 10 may becoated with a polyurea material coating. The polyurea coating willincrease the deflection strength of the pallet support board 10, as wellas increase its impact resistance, surface toughness, and wearresistance. In addition, the polyurea coating can have a texturedsurface to meet any desired friction characteristics. In an embodimentof the invention, a substrate such as a low, medium, or high densityfiber board, or plywood can be coated with polyurea foam. A contemplatedpolyurea coating that may be used is Line-X or Bullet-Liner, availablefrom Burtin Polymer Laboratories of Cartersville, Ga.

FIGS. 5 through 8A and 14 show a top frame 100 formed from a structuralthermoset foam material in accord with an embodiment of the presentinvention. The top frame 100 has a pair of substantially parallel sidesor legs 102 and a pair of substantially parallel ends or legs 104. Thesides 102 and ends 104 are connected to form a generally rectangularunitary frame structure 106 having a central opening 107. The framestructure 106 can be sized in accord with its intended use. The framestructure 106 has an inner layer 105 and outer surface 109, includingupper surface 108 and a lower surface 110. The upper surface 108 andlower surface 110 are separated by foam having a thickness 112. Thethickness 112 typically is on the order of ¼ to 1½ inches, but may beany thickness suitable for its intended application. In an embodiment,the top frame 100 includes one or more bracing members extending betweenthe sides 102 and/or ends 104 and/or corners.

At least one of the sides 102 or ends 104 includes a tapered section 114along an outer edge. It will be understood that the tapered sections 114need not be on both the sides 102 and ends 104. Furthermore, as shown inFIG. 8A, the tapered sections 114 may extend substantially along theentire length of the ends 104 and/or sides 102. In one embodiment, thetapered sections 114 are tapered from both the upper surface 108 andlower surface 110. The tapered sections 114 are sized and located toaccept forklift tines during handling and transport. The frame structure106 also includes banding slots 116 on at least one of its upper surface108 or lower surface 110 to accommodate bands used to secure the topframe 100 to an associated pallet.

Suitable thermoset foam materials can include polyurethane foam,urethane foam, epoxy foam, phenolic foam, syntactic foam, polyasparticfoam, and hybrids of these foams. In a preferred embodiment,polyurethane foam is used. The polyurethane foam material is made in thesame general process and with the same general characteristics asdescribed above with respect to the pallet support board 10.

In an embodiment, the frame 100 is formed such that the foam varies indensity along the thickness 112 of the frame structure 106 to have adensity greater nearest the outer surface 109, including upper and lowersurfaces 108 and 110, than in the center of the thickness 112. Thedensity can vary continuously across the thickness 112, or there can betwo or more discrete layers of similar density, e.g., an inner densityand an outer (i.e., skin) density. In other embodiments, the top frame100 is a generally uniform density throughout the thickness 112. Thedensity of the foam material near the outer surface 109, and upper andlower surfaces 108 and 110 are such that the foam creates a hard outershell. Such material may include a “self-skinning” foam as describedabove. A frame 100 made by this method weighs approximately seven toeight pounds. In one embodiment, at least portions of the upper surface108 and/or lower surface 110 of the top frame 100 have an exterior skinwhich is rubberized or texturized to help prevent slippage between thetop frame 100 and the load with which it is used.

In another embodiment, the finished foam top frame 100 may be coatedwith a polyurea material coating. The polyurea coating will increase thedeflection strength of the top frame 100, as well as increase its impactresistance, surface toughness, and wear resistance. In addition, thepolyurea coating can have a textured surface to meet any desiredfriction characteristics. In an embodiment of the invention, a substratesuch as a low, medium, or high density fiber board, or plywood can becoated with polyurea foam. A contemplated polyurea coating that may beused is Line-X or Bullet-Liner, available from Burtin PolymerLaboratories of Cartersville, Ga.

In an embodiment, the top frame 100 is molded using the same process asdescribed above with respect to the pallet support board 10. Similarly,the top frame 100 can be made from a foam or other substrate, and coatedwith polyurea material as disclosed above with respect to the palletsupport board 10. The polyurea material may be textured to include anydesirable friction characteristics.

FIG. 14 is a perspective cross-sectional view of a top frame 100 made inaccord with an embodiment of the present invention in which aself-skinning foam is used. The top frame 100 includes an outer layer orskin 111 formed by the process 600 of the present invention. The topframe 100 also includes an inner layer 105. The inner layer 105 isessentially uniform in density, while the outer skin 111 is more densethan the inner layer 105. The outer skin 111 is durable and hard towithstand and resist cuts, abrasions and wear. The pallet board 10,pallet 200, insulated tote 400, and dolly 500 made with theself-skinning foam of this method will have a similar structure.

FIG. 9 shows a pallet 200 in accord with an embodiment of the presentinvention. The pallet 200 has a deck 202 with an inner layer 203 andouter surface 205 having an upper surface 204 and a lower surface 206.Extending from the lower surface 206 are a plurality of legs 208. Thelegs 208 support a load placed on the upper surface 204. A thickness 210extends between the upper surface 204 and lower surface 206. A typicalthickness 210 is on the order of ¼ to 1½ inches, but the deck 202 can beof any suitable thickness for its intended application. The deck 202also includes a pair of opposing ends 212, and a pair of opposing sides214. The pallet 200 can be made in any size suitable for itsapplication.

In one embodiment, at least portions of the upper surface 204 and/orlower surface 206 of the pallet 200 have an exterior skin that isrubberized or texturized to help prevent slippage between the pallet 200and the load with which it is used. In another embodiment, the uppersurface 204 includes indented portions 218 corresponding to the legs 208of a second pallet 200 for stacking one pallet 200 on top of another.

The pallet 200 is also made of a thermoset foam material. Suitablethermoset foam materials can include polyurethane foam, urethane foam,epoxy foam, phenolic foam, syntactic foam, polyaspartic foam, andhybrids of these foams. In a preferred embodiment, polyurethane foam isused. The polyurethane foam material is made in the same general processand with the same general characteristics as described above withrespect to the pallet support board 10.

In an embodiment, the foam varies in density along the thickness 210 ofthe deck 202 such that the density is greater nearest the outer surface205, including surfaces 204 and 206, than in center of the thickness210. The density can vary continuously across the thickness 210, orthere can be two or more discrete layers of similar density, e.g., aninner density and an outer (i.e., skin) density. In other embodiments,the pallet 200 is a single density throughout the thickness 210. Thedensity of the foam material near the outer surface 205, includingsurfaces 204 and 206 are such that the foam creates a hard outer shell.Such material may include a “self-skinning” foam as described above.

In another embodiment, the finished foam pallet 200 may be coated with apolyurea material coating. The polyurea coating will increase thedeflection strength of the pallet 200, as well as increase its impactresistance, surface toughness, and wear resistance. In addition, thepolyurea coating can have a textured surface to meet any desiredfriction characteristics. In an embodiment of the invention, a substratesuch as a low, medium, or high density fiber board, or plywood can becoated with polyurea foam. A contemplated polyurea coating that may beused is Line-X or Bullet-Liner, available from Burtin PolymerLaboratories of Cartersville, Ga.

FIGS. 18 through 20 and 22 through 23 show an insulated tote 400 ofembodiments of the present invention. The tote 400 includes a pair ofopposing side walls 402 and a pair of opposing end walls 404 and lid406. As shown in FIGS. 22 and 34, it also can include a lid 406 having afirst side 408 and a second side 410.

In one embodiment, the tote 400 includes a liner 412 made of aself-skinning rigid urethane foam as described above to form an innerlayer 413 and outer surface 415. It has been found that theself-skinning rigid urethane foam insulates better than currentpolystyrene liners, or other insulating materials. Moreover, theself-skinning foam is much more durable. Its hard outer skin isresistant to abrasions, cuts and wear. The liner 412 is sized and shapedto be inserted into the tote 400. The tote 400 also includes aself-skinning urethane foam cover 414 to be placed on top of the liner412, and still allow the lid 406 to completely close.

In another embodiment, the tote 400 is completely made of self-skinningrigid urethane foam, including the side walls 402, end walls 404, andlid 406. In a third embodiment, all but the lid 406 is made ofself-skinning rigid urethane foam. The tote 400 in these two embodimentsdoes not require a liner 412, but one may be provided for additionalinsulation.

In a further embodiment a dolly 500 is provided in FIGS. 16, 17 and 21.The dolly 500 has includes a body 502. The body 502 includes a caster504 at each corner. The body 502 includes an elevated edge 506 and anopening 508 in its center. The body has an inner layer 510 and outersurface 512. Current dollies are made using a rotomold process known inthe art. Current dollies are hollow and made of a thermoplastic. Dolliesare subject to rough treatment. The dolly 500 of an embodiment of thepresent invention is made of the self-skinning urethane foam asdescribed above to create the inner layer 510 and outer surface 512.This provides a more durable dolly. The outer skin is hard and resistsabrasions, cuts and wear better than thermoplastic dollies.

In one embodiment of the invention, the decks 12, frame structure 106and deck 202 of the pallet support board 10, top frame 100, and pallet200 can include a reinforcing material disposed within their respectivethicknesses 18, 112, and 210. The reinforcing material can be any one ormore of woven or continuous strand glass matting, glass fiber, choppedfiberglass, metal tubing, plastic tubing, pultruded glass rod, graphitefibers, Honeywell's Spectra® brand polyethylene fibers, microballoons,nanomaterials, wood or balsa fragments or dust, polyester fibers orcomponents, and shaped metal plates. Other suitable reinforcingmaterials can also be used. In a preferred embodiment, the reinforcingmaterial is a fiberglass or polyester continuous strand mat or Hi-Lofiberglass mesh. These reinforcing materials can be provided by SuperiorFibers, LLC, of Bremen, Ohio or Fiberboard Industries of Amsterdam, N.Y.The material is placed in the mold before either injection or pouring.

FIGS. 10 through 13 show several examples of reinforcing materials thatmay be used with either of the pallet support board 10, top frame 100,or pallet 200. FIG. 10 shows in cross-section of thickness 18 of a deck12 with a fiberglass matting or other fiber reinforcing material 300disposed within. The matting or fiber 300 can be oriented to extendalong one or more directions of the deck, or in a cross-hatch pattern.The matting 300 may or may not extend the entire length of the deck.

FIG. 11 shows in cross-section of thickness 18 of a deck 12 with aplurality of tubes 302 for reinforcing the deck 12. The tubes 302 extendalong preferably either the length or width of the deck 12, but may bearranged in both directions. The tubes 302 may or may not extend theentire length of the deck. In embodiments of the invention, the tubes302 can be made of plastic or metal, preferably steel, and can be in avariety of shapes. These shapes can include round, square, T-shapes,L-shapes, I-shaped, or any other suitable shape.

FIG. 12 shows in cross-section of thickness 18 of a deck 12 with aplurality of pultruded glass rods 304 for reinforcing the deck 12. Therods 304 extend along preferably either the length or width of the deck12, but may be arranged in both directions. The rods 304 can be in avariety of shapes. These shapes can include round, square, T-shapes,L-shapes, I-shaped, or any other suitable shape.

FIG. 13 shows in cross-section of thickness 18 of a deck 12 with aplurality of plates 306 for reinforcing the deck 12. The plates 306extend along preferably either the length or width of the deck 12, butmay be arranged in both directions. The plates 306 may or may not extendthe entire length of the deck. In embodiments of the invention, theplates 306 can be made of plastic or metal, preferably steel, and can bein a variety of shapes. These shapes can include M-shaped as shown,V-shaped, X-shaped, or any other suitable shape.

It will be understood that although FIGS. 10 through 13 were discussedwith respect to a deck 12 of a pallet support board 10, the principleswill apply equally to frame structure 106 and deck 202 of the top frame100, pallet 200, insulated tote 400, and dolly 500 embodiments. In anembodiment of the invention, the reinforcing materials are placed byhand in the tool cavity before the foam mixture is poured or injectedinto the tool cavity. Hand placement would be appropriate for largerreinforcing materials such as steel rods and glass matting.Alternatively, where the reinforcing material would permit, thereinforcing material can be mixed with foam mixture either prior to orduring the injection molding process.

While the invention has been particularly described with respect topallet support boards, top frames, pallets, dollies, and totes, theinvention may also be used with other materials used to transport andstore goods and materials, including top caps, bulk bins, or othersuitable applications. Many of these items will be in one piece witheach of the components integrally connected or formed with the othercomponents.

While the specific embodiments have been illustrated and described,numerous modifications come to mind without significantly departing fromthe spirit of the invention and the scope of protection is only limitedby the scope of the accompanying Claims.

1. A top frame comprising: a pair of substantially parallel sides; apair of substantially parallel ends connected to the sides to form agenerally rectangular frame structure having an inner layer and an outersurface, the frame structure having a thickness; and wherein the topframe is made from a thermoset foam material, the thermoset foammaterial varying in density along the frame structure thickness suchthat the density of the thermoset foam material is greatest nearest theouter surface to form a hard outer shell.
 2. The top frame of claim 1wherein the thermoset foam material includes at least one foam materialselected from the group consisting of polyurethane foam, urethane foam,epoxy foam, phenolic foam, syntactic foam, and polyaspartic foam.
 3. Thetop frame of claim 1 wherein at least one of the pair of sides or endseach includes sections tapered across their thickness.
 4. The top frameof claim 1 further including a fire retardant material mixed with thethermoset foam material.
 5. The top frame of claim 1 wherein the densityvaries continuously across the thickness.
 6. The top frame of claim 1wherein the thickness includes a layer having a first inner density anda second outer density greater than the first inner density.
 7. The topframe of claim 1 wherein the density is generally uniform across thethickness.
 8. The top frame of claim 1 wherein at least a part of theframe structure has an exterior skin with a texturized surface. 9.(canceled)
 10. The top frame of claim 1 wherein the frame structureincludes at least one reinforcing material selected from the groupconsisting of fiberglass matting, fiberglass fiber, metal tubing, metalplating, plastic tubing, pultruded fiberglass rod, shaped metal,microballoons, nanomaterials, wood, polyester matting, and polyesterfibers.
 11. The top frame of claim 10 wherein the reinforcing materialis a continuous fiberglass strand mat.
 12. The top frame of claim 1wherein the thermoset material includes a filler.
 13. The top frame ofclaim 12 wherein the filler is selected from the group consisting ofceramic microballoons, calcium carbonate, wollastonite, and glass. 14.The top frame of claim 12 wherein the filler comprises ceramicmicroballoons.
 15. The top frame of claim 1 wherein the thermoset foammaterial is self-skinning.
 16. A top frame for use in combination with atransport item, such as a pallet, carrying goods, the top framecomprising: a unitary frame formed from a thermoset foam having aninterior foam portion and an exterior surface foam portion, the interiorfoam portion having a first foam density and the exterior surface foamportion having a second foam density greater than the first foamdensity, the exterior foam portion forming a hard skin surrounding theinterior foam portion.
 17. The top frame of claim 16 wherein the unitaryframe comprises: a first leg; a second leg integrally connected to thefirst leg by an integrally formed first corner portion; a third legintegrally connected to the second leg by an integrally formed secondcorner portion; a fourth leg integrally connected to the third leg by anintegrally formed third corner portion, the fourth leg integrallyconnected to the first leg by an integrally formed fourth cornerportion, wherein the first, second, third, and fourth legs form agenerally rectangular shape having an open central portion.
 18. The topframe of claim 16 wherein the thermoset foam is self-skinning.
 19. Thetop frame of claim 16 wherein the thermoset foam includes at least onefoam material selected from the group consisting of polyurethane foam,urethane foam, epoxy foam, phenolic foam, syntactic foam, andpolyaspartic foam.
 20. The top frame of claim 16 wherein the thermosetfoam includes a filler.
 21. The top frame of claim 20 wherein the filleris selected from the group consisting of ceramic microballoons, calciumcarbonate, wollastonite, and glass.